Process of refining clay



Feb. 21, 1939. Y sl C. LYQNS 2,147,774

PROCESS 0F REFINING CLAY Filed July 14, 1956 .,atented Feb. 21,1939

UNiTEc STATES EROCESS F REFINING CLAY ASanford C. Lyons, Bennington, Vt., assignor to Bird Machine .00., Walpole, Mass., a corporation of Massachusetts Application July 14, 1936, Serial N0. 90,474

'i Claims.

This invention relates to a process of refining lay more particularly with the objective of proucing a rened clayvproduct of especial value 1 the manufacture ofrbody-lled papers and Dated or surface-filled printing papers, for iniance, magazine and book papers, coated cardoards, paperboards, etc. For such purposes, it l desirable that paper be possessed of such charcteristics as high whiteness, smoothness, gloss, nd opacity and thus be capable Yof receiving lean-cut imprints with minimum showirough to the opposite fa'ce of the paper.

The process of the present invention comprises iemical and mechanical treatments of clay that Jntribute to the realization of the'aforemenoned objective. Thus, the clay whilev in aqueis suspension is put through a chemical decolizing treatment that serves to eliminate color :tributable to ferruginous or other compounds resent as impurities therein; and while in aque- 1s suspension, the clay is also subjected to cenifugation that throws out of suspension onto 1e centrifuge wall a fraction consisting subantially only of the comparatively coarse parcle size clay and impurities, leaving in the susension or eiiiuent from the centrifuge a fracon consisting substantially only of comparavely ne clay particles below a predetermined irticle size, which latter fraction is recovered om suspension and by reason of its content of )mparatively very fine and colloidal clay parties is eminently useful in paper-coating compotions and as a'ller or 'loader in papermaking ocks. By virtue of the comparatively very fine ze and thede'colorized condition of the ne frac- Jn recovered from suspension or eluent leavg the centrifuge, papers body-filled or surfacelated with compositions containing such recov- `ed fraction are of excellent whiteness, homorneity or smoothness of surface, gloss, and opac- 7- The accompanying drawing illustrates scheatically the invaention hereof, including a con all as coloring impurities, particularly ferric l oxide or other coloring ferruginous compounds,

is first admixed with water to form a substantially homogeneous and fluent suspension of moderately high solids content, preferably a suspension of about 20% to 35% solids content.- 5 The suspension is then treated with a suitable reducing agent-or decolorizing chemical, such as sulphurous acid or sodium bisulphite admixed with zinc, e. g., zinc dust, hyposulphurous acid, sodium hyposulphite, or the like, which serves 10 to transform the ferric oxide and other 'coloring compounds to colorless; water-soluble compounds.` In practice, the decolorizing treatment may be carried outv in a mixing `tank with the addition of the reducing agent or decolorizing chemical in excess of that established to decolorize the coloringV compounds as far as possible. In order to prevent the decolorized, dissolved impurities from resuming their original coloration of the clay by reason of oxidation, action of light thereupon, etc., it is preferable to rinse or wash the decolorized clay suspension one or more times with considerable water, the rinsing or rinsings being followed by the decantationof the rinsing water carrying the dissolved decolorized impurities from the suspension. The treatment of the clay suspension with the decolorizing chemical may be performed either before or after coarse impurities, such as mica and sand, have been removed from the suspension by settling or otherwise. Because of the high concentration of solids in the suspension, only a comparatively small amount of decolorizingv chemical is necessary to create in the suspension ample concen-l tration of such chemical for accomplishing the desired decolorizing reaction upon the coloring compounds.

Once the clay has been decolorized, a suitable dispersing or deflocculating agent, such as sodium silicate, may be admixed with the decolorized aqueous clay suspension in comparatively small amount, say, about 1%, based on the solids content of the suspension, for the purpose of deiiocculating such aggregates of intrinsically ne clayv particles as may exist in the particular clay constituting the raw material or as may tend to develop in an aqueous suspension prepared from such clay. Such treatment of the aqueous clay suspension with a dispersing or deocculating agent tends to increase the yield of the desired fine clay fraction recoverable upon centrifugation of the suspension. The increased yield in recovery of ne particles or ne fraction is attributable in substantial measure to the fact that the dispersing agent for the clay produces such a drastic decrease in viscosity of the clay slip that there is a greatly diminished tendencyfor the entrainment or entanglement of the :dige clay particles with the coarser ones las the coarser ones are caused to subside or deposit out during centrifugation of the slip. The clay suspension containing the dispersing or deocculating agent may, as illustrated in the drawing, then be delivered at appropriate solids content, say, about 20% to 35%, to a continuous ow centrifuge Ill, for instance, ofthe type illustrated and described in detail in my patent application'Serial No. l756,954, filed December 11, 1934. Such centrifuge includes, as shown, a frusto-conical shell and a propelling screw Il which functions to;

discharge solids depositing on the internal wall oi' the shell through the small diameter end of the shell as substantially grit-'free suspension is being emitted through its large diameter end. y

The suspension is fed into the centrifuge preferably adjacent to' its small diameter end, thereby causing the suspension to traverse substantially the full length of the centrifuge'and thus be acted upon by centrifugal force for substantially the maximum period, of time commensurate with vthe particular volumetric now of suspension beor otherwise, such impurities are also deposited along with the comparatively coarse clay fraction on the centrifuge wall. The coarse clay solids and oversized impurities are received from the small diameter end of the centrifuge in an annular trough I2 and are discharged through a pipe i3, whence they may be recovered and `used in the manufacture of certain classes of paper, ceramicaand for other purposes, such as for lling rubber compounds, for instance, in rubber compounds to b e molded into vstoragebattery boxes or to be fabricated into floor coverings'. The substantially grit-free suspension or eiiiuent containing the comparatively very-,fine and colloidal clay particles is received from the large diameter end of the centrifuge in an annular trough I4 and may,4 if desired,v be delivered therefrom through a pipe l5 through a rotary or other suitable screen I6 which serves to eliminate from the suspension such fibrous material as bark, wood, or other floating trash.

. The suspension containing the comparatively ne clay fraction may then be subjected to suitable treatments for the recovery of such fraction therefrom. While the recovery treatments mayv be those disclosed in my application Serial No. 2,369, led January 18, 1935, and involve the progressive separation of the very fine clay solids from. suspension in an electrophoretic centrifuge,

the present invention comprehends other simple and effective steps for recovering the ne clay fraction from suspension. I'hus, the suspension of the ilne clay fraction or eiiiuent from the centrifuge may advantageously be treated with a suitable occulating agent, such `as alum, in the amount of, say, about 1%, based on the dry weight of the solids in suspension, whereupon'the iiocculated ne clay solids may then be readily recovered from the suspension byltration in iilter presses or the like such as are currentlyused in the clay industry.

The decolorized fine clay fraction as recovered by filtration may be added as a filler to papermaking stock in the beater engine; or it may be used in preparing paper-coating compositions, which are usually made up as aqueous'compositions with suitable binding or sizing agents, such as casein, and applied by'spreading on the surface of the prefabricated paper sheet. While it is possible to ship the fine fraction as filterpressed cakes of substantial water content, e. g., 30%--,-from lthe clay works to a paper-making mill 'and this expedient has, in fact, on occasion been adopted .with good results, for instance, with what appears to be worthwhile improvement in the retention of the clay particles by papermaking stock in'the beater engine, yet, it is ordinarily preferable to dry the ltered fine clay fraction when it is to be shipped from the clay works to the papermaking mill so as to facilitate its handling and lower the transportation cost. Depending upon the particular qualityy or origin of crude clay and thefineness of particle size desired in the recovered fine clay fraction, about Ifraction for use in the highest grade of bodyiilled and surface-coated papers. Thus, clays quarried at Bennington, Vermont, were found to yield the desired fine clay fraction in the amountl of about 30% to 40%, based on the dry solids of the original or freshly quarried clay. Of course, the conditions of operation of the centrifuge in which fractionation of the suspension is effected, including such factors as the eective diameterI oi.' the centrifuge, its rate of rotation, the rate of flow of suspension therethrough, the solids content of the suspension-being centrifuged, and the viscosity of the suspension as affected byA dispersing or deocculating agents. are controlled so as to cause 'an 4emission from the centrifuge of a ilne fraction in suspension containing particles of the particular desired ilne particle size and representing a particular percentage of the solids of the original clay, which percentage may, as already indicated, varyV considerably.

While the chemical decolorizing Vtreatment might be omitted in the practice of the process hereinbefore described, it is of advantage in that it enhances the whiteness of the fine clay frac-- tion and, accordingly, its value for paper-loading and paper-coating purposes. Should the chemical decolorizing treatment be omitted, one may proceed to fractionate the clay suspension to "which the dispersing or deilocculating agent has been added by the centrifugal treatment hereinbefore described either before or after coarse or oversized impurities, such as mica and sand, have been remove'd by settling or otherwise from the suspension. For instance, in respect of clays ,quarried at Bennington, Vermont, the aqueous has been described as the instrumentality for effecting the fractionating step hereof because it permits of continuous and more economical operation and because the conditions of centrifugation can be maintained constant in the conduct of the process to yield a line clay fraction of denite and reproducible quality, it is-possible to use a discontinuous or batch type of centrifuge on whose wall a coarse solids fraction is accumulated or deposited until a certain thickness of solids layer of accumulation is had and which is stopped to discharge such solids layer. In such latter event, the effective centrifugal force at play on the suspension varies as the thickness of the layer or deposit on the centrifugal wall increases and the detention period or effective volumetric capacity in the centrifuge, which also'aiects the quality or neness of the ne clay fraction recoverable, also varies even more drastically with the thickness of the layer or deposit; and additional labor cost and lower outputare consequences of the necessary interruptions or stoppages of the centrifuge.

So far as concerns certain subject matter, this application is a continuation-in-part of my application Serial No. 2,369, led January 18, 1935.

I claim:

1. A process of refining clay containing coloring impurities to produce a clay product particularly adapted for use in high grade body-lled and surface-coated papers, which comprises mixing such clay with water to form an aqueous clay suspension, treating the resulting suspension with a chemical capable of decolorizing andY dissolving said coloring impurities, washing the clay suspension with Water so as to carry away therefrom the decolorized and dissolved impurities, adding to the washed suspension a dispersing agent for the clay, continuously centrifuging the resulting ,decolorized and dispersed clay suspension under.

substantially constant solids-depositing conditions, including substantially constant effective centrifuging force, to remove a substantial coarse solids fraction therefrom,including the coarse clay particles, thereby leaving therein throughout the centrifuging operation substantially only comparatively ne and colloidal clay particles below a predetermined particle size, and recovering from the resulting suspension said comparatively ne and colloidal particles.

2. A process of refining clay containing coloring impurities, including ferric oxide, to produce a clay product particularly adapted 'for use in high grade body-filled and surface-coated papers, which comprises mixing such clay with Water to form an aqueous clay suspension, treating the resulting suspension With a reducing agent capable of transforming said ferric oxide and other coloring impurities into substantially colorless, water-soluble compounds, washing the clay suspension with water so as to carry away therefrom the decolorized` and dissolved impuritiesM adding to the washed suspension a dispersing agent for the clay, continuously centrifuging the resulting decolorized and dispersed clay suspension under substantially constant solids-depositing conditionsjincluding substantially constant effective centrifuging force, to remove a substantial coarse solids fraction therefrom, including the coarse clay particles, thereby leaving' therein throughout the centrifuging operation substantially `only comparatively ne and-colloidal clay'particles below a predetermined particle size, and recovering from the resulting suspension said compara.- tively fine and colloidal clay particles.

3. A process of rening clay containing coloring impurities, including ferric oxide, to produce a clay product particularly adapted for use in high grade body-filled and surface-coated papers,

,which comprises mixing such clay with water to form an aqueous clay suspension of about 20% to 35% solids content, treating the resulting .suspension with a reducing agent capable of transforming said ferric oxide and other coloring impurities into substantially colorless, Water-soluble compounds, washing the clay suspension with Water so as to carry away therefrom the decolorized and dissolved impurities, adding to the Washed suspension a dispersing agent for the clay, continuously centrifuging the resulting decolorized and dispersed clay suspension at a solids content of about to 35% and under suby impurities, including ferric oxide, -to produce a clay product particularly adapted for use in high grade body-filled and .surface-,coated papers, which comprises mixing such clay with water to form an aqueous clay suspension, treating the resulting suspension with a reducing agent capable of transforming said ferric oxide and other coloi'- ing impurities into substantially colorless, watersoluble compounds, Washing the clay suspension with water so as to carry away therefrom the decolorized and dissolved impurities, adding to the washed suspension a dispersing agent for the clay, continuously centrifuging the resulting decolorized and dispersed clay suspension under substantially constant solids-depositing conditions, including substantially constant effective centrifuging force, to remove a substantially coarse solids fraction, including coarse clay particles, corresponding with a residuum therein of about 50% to 25%, based on the solids of the original clay suspension, of substantially only comparatively iine and colloidal clay particles below a predetermined particle size throughout said centrifuging operation, and recovering from the resulting suspension said comparatively ne and colloidal clay particles. k

5. A process of refining clay containing coloring impurities, including ferric oxide, to produce a clay product particularly adapted for use in high grade body-filled and surface-coated papers, which comprises mixing such clay with Water to form an aqueous clay suspension of about 20% to 35% solids con-tent, treating the resulting suspension with a reducing agent capable of transforming said ferric oxide and other coloring m.

.` fraction; including coarse clay particles, corresponding with a residuum therein of about 50% to 25%, based on the solids of the 'original clay suspension, oi substantially only comparatively fine and colloidal clay particles below a predetermined particle size throughout said centrifuging operation, and recovering from the resulting suspension said comparatively flne and colloidal clay particles.

6. A process of renning clay containing coloring impurities to produce a clay product particularly adapted for use in high grade body-lled and surface-coated papers, which comprises mixing such clay with water to form an aqueous clay suspension, treating the resulting suspension with a chemical capable of decolorizing and dissolving said colored impuritieawashing out the decolorized and dissolved impurities substantially com- Y pletely from the -clay suspension, adding to the washed suspension a dispersing agent. for the clay, continuously centrifuging the resulting de coiorized and dispersed clay suspension under substantially constant solids-depositing conditions, including substantially 'constant effective centriiuging force, to remove a substantial coarse solids fraction therefrom, including the-coarse particles.

culating and recovering fromv the resulting suspension said comparatively iine clay particles.

7. A process of rening clay containing coloring impurities, including ferric oxide, to produce a clay product particularly adapted for use in high grade body-nlled and surface-coated papers, which comprises mixing such clay with water to, form an aqueous clay suspension, treating the resulting suspension with a reducing agent capable of transforming said ferric oxide and other coloring 'impurities into substantially colorless, water-soluble compounds, washing outthe substantially colorless, water-soluble compounds substantially completely from Ithe clay suspension, adding to the washed suspension a dispersing agent for the clay, continuously centrifugingthe resulting decolorized and dispersed clay suspension under substantially constant solids-depositing conditions, including substantially Vconstant effective centriiuging i'orce, to remove a substantial coarse solids fraction therefrom, includingthe' coarse clay particles, thereby leaving l therein substantially only fine and colloidal clay particles below a predetermined particle size throughout said centriiuging operation, and occulating and ltering out from the resulting suspension said comparatively ilne and colloidal clay SANFORD C. LYONS. 

